Fixed-Fin Mandibular Splints for Precise Jaw Titration

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Solution Overview

Problem

Existing mandibular advancement devices face challenges in precise titration, durability, patient comfort, and consistency due to manual fabrication methods, leading to increased residual monomers and decreased compliance.

Innovation Solution

Digitally designed and milled mandibular advancement devices comprising upper and lower splints with fixed fins, allowing for accurate jaw advancement without adjustment screws or straps, using CAD processes and materials like PEEK for enhanced durability and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual artisanal fabrication methods are used to create mandibular advancement devices, then customization to individual patient anatomy is possible, but manufacturing precision and consistency are reduced

Engineering Contradiction:

Improvecustomization to individual patient anatomyVSAvoidprecision of device design and titration

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent transitions from manual fabrication to digital manufacturing processes (CAD/CAM), changing the production parameters from artisanal to automated. This enables precise control over device geometry, fin positioning, and mandibular advancement increments while maintaining patient-specific customization through digital impressions and modeling.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical manual fabrication process with a digital design and automated milling system. The CAD software allows precise positioning of fins and determination of mandibular advancement settings, while the automated milling machine reproduces these designs with high precision, eliminating the variability inherent in manual fabrication.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If adjustment screw mechanisms and straps are used for titration, then mandibular advancement can be adjusted, but device complexity and number of components increase

Engineering Contradiction:

Improveadjustability of mandibular advancementVSAvoidnumber of components including screws and straps

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the adjustment screw mechanism and straps from the device design. Instead, it incorporates multiple pre-fabricated splints with different fixed fin positions directly into the appliance. This eliminates the need for separate adjustment components while maintaining titration capability through selective use of different splints.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the titration function into multiple discrete splints, each with a specific fixed advancement setting. Rather than one adjustable mechanism, the system divides the adjustment range into several predetermined increments, allowing the clinician to select the appropriate splint for the desired level of mandibular advancement.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple components, straps, and screws are used in device design, then adjustability is provided, but durability and reliability decrease

Engineering Contradiction:

Improveadjustability through multiple componentsVSAvoiddurability of device

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the adjustment mechanism and the structural components into a single integrated splint design. Each splint is fabricated as one piece with fins and retention features built-in, eliminating the need for separate screws, straps, and adjustment blocks. This integration reduces potential failure points and improves overall device reliability.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If manual layering of monomers is used in fabrication, then device can be customized, but residual monomer levels increase

Engineering Contradiction:

Improvecustomization capabilityVSAvoidresidual monomer levels

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the chemical manual layering and curing process with a mechanical automated milling process. The splints are milled from pre-cured polymer blocks or similar materials, eliminating the need for monomer layering and curing. This substitution dramatically reduces or eliminates residual monomer content while maintaining customization through digital design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12186232B2Mandibular advancement device

Publication Date: 2025.01.07 PROSOMNUS SLEEP TECHNOLOGIES INC

AI summary

Disclosed herein are mandibular advancement devices comprising an upper splint and a lower splint, where the upper splint comprises one or more upper fins, where each upper fin is located at a distance UD from back of the upper splint; the lower splints comprise one or more lower fins, where each lower fin is located at a distance LD from back of the lower splint; where the position of the upper and lower fins is unchangeable. Also disclosed are methods of reducing partial constriction of airway during sleep for a patient, the method comprising identifying a patient in need thereof; and administering to the patient the disclosed mandibular advancement device. Also disclosed are methods of manufacturing a mandibular advancement device, the method comprising obtaining measurements from a patient's dentition; digitally designing a mandibular advancement device; and milling the mandibular advancement device.